Based on the constructed theoretical ternary phase diagrams of water/dimethyl sulfoxide (DMSO)/polyacrylonitrile (PAN) terpolymer system, the phase separation behavior for PAN fibers preparation was investigated. Theoretical ternary phase diagrams were determined by the extended Flory-Huggins theory. To investigate the temperature dependence of theoretical ternary phase diagrams, all binary interaction parameters at different temperatures were determined accurately and thoroughly revisited. From numerical calculations, it was found that a small quantity of water was needed to induce phase demixing. Meanwhile, the cloud point data of the system for more dilute PAN terpolymer solutions were determined by cloud point titration, and the cloud point data for more concentrated PAN terpolymer Solutions were calculated by Boom's linearized cloud point (LCP) curve correlation. Furthermore, the morphology of PAN fibers was investigated by using scanning electron microscopy (SEM). With increasing the concentration of PAN terpolymer solutions as well as the quenching depth, the morphology of PAN fibers turns from large open channels to small bead-like structures, accompanying with a reduction of the porosity of PAN fibers. Judging from our investigation, it was clear that. the final morphology of PAN fibers was mainly determined by phase separation in fiber-forming process. (C) 2008 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 47: 261-275, 2009